Course description

This course is designed to provide in-depth knowledge and practical competence in the design, operation, configuration, maintenance, and troubleshooting of Fire & Gas Detection Systems in accordance with international standards and industry best practices (e.g., NFPA 72, ISA TR84.00.07, IEC 61511).
The course explores the fundamental principles of hazard detection, the technologies used to sense flammable gases, toxic gases, smoke, heat, and flame, as well as the integration of these detection systems into broader Safety Instrumented Systems (SIS), Emergency Shutdown (ESD) systems, and Building Management Systems (BMS). It provides insights into the performance-based design of detection coverage and alarm logic configuration, and how to analyze detection gaps and optimize sensor layout.
Participants will study the key elements of detection technologies—such as catalytic bead, infrared (IR), ultrasonic acoustic, electrochemical, photoionization, flame ionization, optical flame detectors, smoke detectors, and thermal sensors. These technologies will be reviewed in the context of their working principles, capabilities, limitations, response times, susceptibility to false alarms, and environmental performance.
Further, the course dives into the application of risk-based mapping tools and the role of computational fluid dynamics (CFD) in designing optimal fire/gas detector placement. The participants will be trained on the Fire and Gas Mapping approach, understanding gas dispersion models, flame field analysis, and how to interpret hazard scenarios using simulation software outputs (e.g., Detect3D, FLACS, or similar).
The course emphasizes the integration and communication protocols used in modern FGDS such as HART, Modbus, Profibus, and wireless HART. Attendees will learn how to manage data flow between the field detectors and control systems such as PLCs, DCSs, SCADA, or Safety Systems using SIL-rated logic solvers.
Real-life case studies will be discussed to emphasize lessons learned from major fire and gas incidents due to inadequate detection systems or failures in alarm management and operator response. Regulatory and compliance aspects will also be addressed, highlighting IEC, NFPA, API, and OSHA recommendations.
Participants will gain hands-on experience with typical detection system hardware including field-mounted detectors, controllers, and alarm interfaces. They will explore routine and predictive maintenance tasks including detector calibration, bump testing, function checks, cleaning, and replacement procedures.

Audience

This course is tailored for professionals involved in industrial safety, instrumentation, maintenance, and plant operations, including:

  • Safety Engineers
  • Instrumentation and Control Engineers
  • Process Engineers
  • Maintenance Technicians
  • E&I Supervisors
  • Fire & Safety Officers
  • Project Engineers
  • Risk and HSE Managers

Prerequisites

Participants should have a basic understanding of:

  • Industrial instrumentation and control systems.
  • Process safety concepts.
  • Hazard identification methodologies (e.g., HAZOP, LOPA) – recommended but not mandatory.
  • Basic electrical and control system knowledge.
  • Familiarity with process plant operations.

Course content

Fundamentals of Fire & Gas Detection Systems
Introduction to Fire and Gas Safety in Process Plants
Risk Factors in Hazardous Environments
Types of Hazards: Fire, Explosion, and Toxic Release
Regulatory Framework (NFPA, OSHA, API RP 14C, IEC 61511)
Fire and Gas System Architecture and Functional Overview
Introduction to Safety Integrity Level (SIL) and Performance Targets
Classification of Hazardous Areas (Zone/Division Systems)
Design Objectives and Typical Layouts of FGDS

Detection Technologies and Sensor Characteristics

Principles of Fire Detection:
o    Smoke detectors (ionization, photoelectric)
o    Heat detectors (rate of rise, fixed temperature)
o    Flame detectors (IR, UV, UV/IR, Multi-spectrum IR)
Principles of Gas Detection:
o    Catalytic, Electrochemical, Infrared, Ultrasonic
Sensor Selection Criteria
False Alarms: Causes and Mitigation
Environmental Effects on Detection
Detector Installation Best Practices and Clearance Guidelines

Fire and Gas Mapping and System Integration
Introduction to Fire & Gas Mapping
3D Modeling and Coverage Simulation
Gas Dispersion Modeling and Flame Coverage Mapping
Software Tools: Detect3D, FLACS, etc.
Interpretation of Mapping Results and Optimization
Alarm Management: Alarm Prioritization, Suppression, Deadband
Integration with PLCs, SCADA, and DCS
Communication Protocols: Modbus, HART, Profibus, Wireless

Maintenance, Calibration, Testing and Troubleshooting
Routine Maintenance Practices
Calibration Procedures for Gas and Flame Detectors
Bump Testing and Detector Function Checks
Troubleshooting Common Issues
Detector Replacement and Sensor Poisoning
Predictive Maintenance and Remote Monitoring
Fire and Gas System Validation and Performance Testing
Case Studies on Maintenance Failures

Emergency Response, Case Studies, and Final Assessment
Role of FGDS in Emergency Shutdown (ESD)
Human-Machine Interface (HMI) and Operator Response
Review of Real-Life Industrial Accidents and FGDS Failures
Emergency Evacuation Plans and FGDS Alarms
Developing and Reviewing FGDS Design Specifications
Final Assessment – Practical Design Exercise + Written Test
Group Discussion and Wrap-Up
Certificate Distribution

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